Thank you for purchasing a Honda generator.

This manual covers operation and maintenance of EM5000SX/EM5000X gen-

erators. All information in this publication is based on the latest product
information available at the time of approval for printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time.without
notice and without incurring any obligation.

No part of this publication may be reproduced. without written permission.

This manual should be considered a permanent part of the generator,and re

main with the generator when sold.

Pay special attention to statements preceded by the following words:

ADANGER: Indicates severe personal injury or death will result if in-

structions are not followed.

m Indicates a strong possibility of severe personal injury or loss of

life if instructions are not followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if

instructions are not followed.

NOTE: Gives helpful information.

If a problem should arise, or if you have any questions about the generator,
consult an authorized Honda dealer.

m The Honda generator is designed to give safe and dependable serv-

ice if operated according to instructions. Read and understand this Owner’s
Manual before operating the generator. Failure to do so could result in person-
al injury or equipment damage.

NOTE: This generator is equipped with a U.S.D.A. qualified spark arrester

which requires periodic maintenance to ensure its effectiveness. It is illegal in
some areas to operate an engine without a spark arrester. Check local laws
and regulations.

1
CONTENTS

CONTENTS .’

GENERATOR’SAFETY:. .................................. 3
COMPONENT IDENTIFICATION ............................ 7
3. PRE-OPERATION CHECK ..... : ............................. 9
4. STARTING THE ENGINE .................................. .13
5. GENERATOR USE. ...................................... .18
6. STOPPING THE ENGINE ................................... .25
l High altitude operation ........... ;. ...................... .26
7. MAINTENANCE..........................................2 7
8. TRANSPORTING/STORAGE ................. ; ............. .36
9. TROUBLESHOOTING. ................................... ~38’
10. WIRING DIAGRAM.......................................4 0
11. SPECIFICATIONS......‘..................................4 2
12. INSTALLATION OF OPTIONAL PARTS ..................... .43
13.. WARRANTY FERVICE ....................................... .49

.:. : ;. .,:

2
 1. GENERATOR SAFETY

l Place the generator on a firm, level surface; avoid loose sand or snow. If
the generator is tilted or overturned, fuel spillage and a fire may result.

l To prevent fire hazards and to provide adequate ventilation, keep the gen-
erator at least 1 meter (3 feet) -away from buildings and other equipment
during operation. Do not place flammable objects close to the generator.

l Children and pets must be kept away from the area of operation due to a
possibility of electric shock or burns from hot components.

l Know how to stop the generator quickly, and understand the operation of
all the controls. Never permit anyone to operate the generator without
proper instruction.

l The generator is a potential source of electrical shocks if misused. Do not

operate the generator in rain or snow. Do not let the generator get wet,
and do not operate it with wet hands.

0 Gasoline is extremely flammable and is explosive under certain conditions.

l Refuel in a well-ventilated area with the engine stopped. Do not smoke or

allow flames or sparks in the refueling area or where gasoline is stored.

l Do not overfill the fuel tank. After refueling, make sure the tank cap is
closed properly and securely.

l Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may
ignite. If any fuel is spilled, make sure the area is dry before starting the
engine.

l Never run the engine in an enclosed or confined area. Exhaust contains

poisonous carbon monoxide gas; exposure may cause loss of consciousness
and may lead to death.

l The muffler becomes very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffler while it is
hot. Let the engine cool before storing the generator indoors.

l Connections for standby power to a building’s electrical system must be

made by a qualified electrician and must comply with all applicable laws
and electrical codes. Improper connections can allow electrical current
from the generator to backfeed into the utility lines.
3
 Such backfeed may electrocut6 utility company workers or others who
contact the lines during a power outage, and when utility power is restored,
the generator may explode, burn, or cause fires in the building’s electrical
system.

CAUTION: Equipment damage and corrosion from sand, dirt, and water may
occur if the generator is overturned or sinks into a soft surface.

‘4
Read these labels before you operate the generator.

/
FWARNING DO NOT USE INDOORS.EXHAUST GAS CDNTAlNS>
POISONOUSCARBONMONOXIDE.
ATTENTION NE,PASUTlLlSERDANSUNENDROlT FERMEACAUSE
DU RISQUED'EMPOISONNEMENTDU GAZ.
ATENCl(')N NO LO USE EN LUGARES CERRADOS PORQUEEL
\ MONOXIDEDE CARBON0 ESVENENOSO. //

5
 ? CO.. LTD. MADE IN JAPAN Gl 1

EM5000X -
IAl.
HONDA MOTOR CO., LTD.
II am II
MADE IN JAPAN @
Ah
CAUTLUN II AL II Ub II

6
 2. COMPONENT IDENTIFICATION

ENGINE SWITCH (EM5000X)

PILOT LAMP

-.lYlL,Lrl
VOLT R/lCl-CD 1,\
VOLTAGE SELECTOR SWITCH

OIL ALERT LAMP.‘\’ I

ENGINE SWITCH \ \I
CHOKE ROD \
\
\

FUEL VALVE

AIR
CLEANER

:EPTACLES
RECOIL
STARTER
GRIP
TERMINAL
DC CIRCUIT
OIL FILLER CAP
PROTECTOR

DC OUTPUT SWITCH (EMSOOOSX)

TERMINAL

OIL DRAIN PLUG

7
 FUEL METER
FUEL TANK CAP
I

SPARK PLUG
CAP

MUFFLER

8
 3. PRE-OPERATION CHECK
Perform the pre-operation check with the generator on a level surface and the
i’
engine stopped.
1. Engine Oil ,

CAUTION: Engine oil is a major factor affecting engine performance and

service life. Non detergent oils, ‘castor-based oils, and 2-stroke engine dils are
not recommended because they have inadequate lubrictitihg characteris!ics.
Use Honda 4-stroke oil an equivalent high-detergent, premium quality motor
oil certified to meet or exceed U.S. automobil manufacture’s.requirements
for Service Classification SG-SF/CC-CD. Motor oils classified SG.SF/CCCD
will show this designation on the container,

SAE lOW/30 is recommended for general, all-temperature use. Other viscosi-

ties shown in the chart may be used when the average temperature in your
area is within the indicated range.
,. : .’ , ” )
1. Remove the oil filler cap and check the oil level. ,
2. ,lf the. level is low, fill to the top of the oil filler,neck with the recornmel
nded oil. ., I:

NOTE: The Oil Alert System will automatically stop the engine before the
oil level fails below the safe limit. However,.to avoid the inconvenie,nce of an
unexpected shutdown, it is advisable,to visually inspect the oil level regularly.

OIL FILLER OIL FILLER

CAP HOLE

-20 ,o , 20 40 60 80 lOOoF
-30 -20 -10. 0 10 20 30 4o”c
Ambient temperature
2. Fuel

Check the fuel meter and refill the tank if the fuel level is low.
Your engine is designed to use any gasoline that has a pump octane
number (-1 of 86 or higher, or that has a research octane number of
91 or higher. Gasoline pumps at service station normally display the pump oc-
tane number.
We recommend that you use unleaded fuel because it produces fewer engine
and spark plug deposits and extends the life of exhaust system components.

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid get-

ting dirt, dust or water in the fuel tank. Use of a lower octane gasoline can
cause persistent “pinging” or heavy “spark knock” (a metallic rapping noise)
which, if severe, can lead to engine damage.

CAUTION: If “spark knock” or “pinging” occurs at a steady engine

speed under normal load, change brands of gasoline. If spark-knock or
pinging persists, consult your authorized Honda dealer. Failure to do so
is considered misuse, and damage caused by misuse is not covered by
Honda’s Limited Warranty.

Occasionally you may exp’erience light spark knock while operating under heavy
loads. This is no cause for concern, it simply means your engine is operating
efficiently.

Fuel tank capacity: 17.0 II (4.5 US gal)

FUEL METER FUEL FILLER CAP

10
 ‘m ,:
I
l ’ Gasoline is extremely .flammable and is explosive under certain
conditions.
l Refuel in a well-ventilated area with the engine stopped. Do not
~ smoke or allow flames or sparks in the area where the engine is refuel-’
ed- or where .gasoline is stored. ’
l Do not overfill the fuel tank (there should be no fuel in the filler neck).
After refueling, make sure the tank cap is closed properly and
i securely.
l Be careful not to,spill fuel when refueling. Spilled fuel or fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before star-
ting, the engine.
0 Avoid repeated or prolonged contact with skin or breathing of vapor.
KEEP OUT OF .REACH OF CHILDREN.

GASOLINES CONTAINING ALCOHOL

If you’decide to use a gasoline containing alcohol (gasohol), be sure it’s octane
rating is at least as high as that recommended by Honda. There are two types
of “gasohol”: one containing ethanol, and the other containing methanol. Do
not use gasohol that contains more than 10% ethanol. Do not use gasoline
containing methanol .(methyl or wood alcohol) that does not also contain
cosolvents and corrosion inhibitors for methanol. Never use gasoline containing
more than 5% methanol, even if it has cosolvents and corrosion’ inhibitors.
NOTE:
l Fuel system damage or engine performance problems resulting from the use
of fuels that contain alcohol is not covered under the warranty. Honda can-
not endorse the use of fuels containing methanol since evidence of their
suitability is as yet incomplete.
l Before buying fuel from an unfamiliar station, try to find out if the fuel con-
tains alcohol, if it ,does, ‘confirm the type and percentage of alcohol used.
If you notice any undersirable operating symptoms while using a gasoline
that contains alcohol, or one that you think contains alcohol, switch to a
gasoline that you know does not contain alcohol.

11
3. Air Cleaner

Check the air cleaner elements to be sure they are clean and in good condi-
tion. Clean or replace the elements if necessary (page30).

CAUTION: Never run the engine without the air cleaner. Rapid engine wear
will result from contaminants, such as dust and dirt, being drawn through the r
carburetor, into the engine.

ELEMENT e

.’

. .

.,

12
 4. STARTING THE ENGINE

1. Make sure that the AC circuit breaker is. in the OFF position, and that
nothing is connected to the DC terminals.
The generator may be hard to start if a load is connected.

AC ClkUlT BREAKER DC TERM’IidALS

2. Turn the fuel valve to the ON position.

FUEL VALVE
3. Pull the choke rod out td the CLOSE position.

CHOKE ROD

4. Make sure the auto-throttle switch is’ in the.O.FF position, or more time
will be required for warm up. (ERi15000SX only)

AU’TO-TH ROTTLE
SW I’TCH

‘14
I,
., :
5. Start the engine
l With recoil starter:
Turn the engine switch to the ON position.

ITCH
\y
I, .,

ENGINE SWITCH
(EM5000SXI
(EM5000X)

Pull the starter grip lightly until resistance is felt, then pull briskly.

CAUTION: Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter or housing.

.STARTER GRIP

15
 l With electric starter (EM5000SX only):
Turn the engine switch to the START position and hold it there until
the engine starts.

NOTE:
l Do not use the electric starter for more than 5 seconds at a time. If the
engine fails to start, release the switch and wait 10 seconds before operating
the starter again.
l If the generator is equipped with a remote control kit, make sure the switch
on the relay box is turned off, or the engine will not start. ‘I
0 If the speed of the starter motor drops after a period of time, it is an indica-
tion that the battery.should be recharged.

,ENGlNE SWITCH
;

6. When the engine starts, allow the engine switch to return to the ON posi-
tion.

16
7. Push the choke rod to the OPEN position as the engine warms up.

CHdKE RQD

8. If you wish to use the auto-throttle system, turn the auto-throttle switch
to the AUTO position after the engine has warmed up for 2 or 3 minutes.
(EM5000SX only)

NOTE: When a battery is connected for electric starting, choke operation is

automatic, but you can override the automatic choke by manually pulling the
choke rod. If the choke is closed manually, you must also push in the choke
rod manually to allow the choke to open.
:

AUTO-THROTTLE
SWITCH

17
 5. GENERATOR USE

m To prevent electrical shock from faulty appliances, the generator

should be grounded. Connect a length of heavy wire between.the ground ter-
minal and the ground source.
Connections for standby power to a building’s electrical system must be made
by a qualified electrician’ and must comply with all applicable laws and elec-
trical codes. Improper connections can allow electrical current from the gen-
erator to backfeed into the utility lines. Such backfeed may electrocute utility s
company workers or others who contact the lines during a power outage, and
when utility power is restored, the generator may explode, burn, or cause fires
in the building’s electrical s CL

GROUNdTERillNiL
CAUTION:

l Limit operation requiring maximum power (5.0 kVA). to 30 minutes. For

continuous operation, do not exceed the rated power of 4.5 kVA. In either
case, be sure to consider the total power requirements of all connected
appliances.
-z
l Most appliance and power tool motors require more than the rated,operat-
ing current for start-up. To match appliance“power needs to generator
capability, allow a sufficient generator power reserve to ‘accommodate i
motor start-up requirements.

0 Do not exceed the current limit specified for any one receptacle.

NOTE: Appliance and power tool manufacturers usually list rating informa-
tion near the model number or serial number.

18
Oil Alert System

The Oil Alert system is designed to prevent engine damage caused by an in-
sufficient amount of oil in the crankcase. Before the oil level in the crankcase
falls below a safe limit, the Oil Alert system will automatically shut down the
engine (the engine switch will remain in the ON position).

If the Oil Alert system shuts down the engine, the Oil Alert lamp will flash
when you operate the starter, and the engine will not run. If this occurs, add
engine oil (P. 9 1.

OIL ALERT LAMP

19
Auto-throttle System (EM5000SX only)

With .the switch in the-AUTO position, engine speed is automatically reduced

to an idle when all. loads are turned off or disconnected. When appliances are
turned cn or reconnected, the engine resumes the rated speed. At OFF, the
auto-throttle system does not operate.
2:
NOTE:
q AUTO. is, recommended to minimize fuel consumption when no load is
applied.
l The auto-throttle system will not respond to electrical loads of less than
1 ampere.
l The system is not-effective for use with appliances that require only mo-
mentary power. To avoid extended warm-up periods, keep the switch OFF
until the engine reaches operating temperature.

AUTO-THROTTLE
SWITCH

20
I AC applications

1. Start the engine and make sure the pilot lamp comes on. If not, the fila-
ment may be burnt out.

2. Turn the voltage selector switch to either position as required.

NOTE: With the voltage selector switch in the “12OV/24OV” position, y.ou
can use the 120V and 240V receptacles simultaneously. If you are not using
: the 240V receptacle, but you require more power from the 120V twrst-lock
receptacle, then turn the switch to the “12OV” position.
PILOT VOLTAGE SELECTOR
LtMP SWITCH

3. Switch on the AC Circuit Breaker.

AC CIRCUIT BREAKER

21
4. Plug in the appliance.

PLUG

CAUTION
0 Be sure that appliances do ‘not exceed the generator’s rated load capacity
for more than 30 .minutes and that they never exceed .the maximum load
capacity.
Substantial overloading will, switch off the circuit breaker. Marginal over.
loading may not switch off the circuit breaker, but it will shorten the
service life of the generator.
0 If an overloaded circuit causes the AC circuit breaker to switch off, reduce
the electrical load on. the ckcuit, and wait a few minutes before resetting
the circuit breaker.
l Be sure that all appliances are in good working order before connecting
them to the generator. If an appliance begins to operate abnormally, be-
comes sluggish, or stops suddenly, turn off the circuit breaker and the
generator engine switch immediately. Then disconnect the appliance and
examine it for signs of malfunction.

NOTE: This generator,is equipped with an AVR (Automatic Voltage Regula-

tor) for stable voltage supply.

22
 DC operation

The DC terminals may be used for charging 12 volt automotive-type batteries

only.

1. Connect both charging cables to the battery terminals and connect the
? positive (+ 1 cable to the generator’s positive (+ 1 DC terminal.

2. Start the engine.

i
3. Carefully connect the negative (- 1 charging cable to to the generator’s
negative (-1 DC terminal.

DC CIRCUIT
PROTECTOR

NEGATIVE TERMINAL POSITIVE TERMINAL

(BLACK) (RED)

l The battery gives off explosive gases; keep sparks, flames and
cigarettes away. Provide adequate ventilation when charging or us-
ing batteries in an enclosed space.
l The battery contains sulfuric acid (electrolyte). Contact with skin or
eyes may cause severe burns. Wear protective clothing and a face
shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15
minutes and call a physician immediately.

23
l Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and follow
with milk of magnesia or vegetable oil and call a physician.
. KEEP OUT OF,REACH OF CHILDREN.
0 To prevent the possibility of creating a spark near the battery, con-
nect charging cables first to the. battery, then to the generator.
Disconnect cables first at the generator.
l Before connecting charging cables to a battery that is installed in a
vehicle, disconnect the vehicle’s grounded battery cable. Reconnect
‘the vehicle’s grounded .battery cable after the charging cables are
removed. This procedure will prevent the possibility of a short circuit
and sparks if you make accidental contact between a battery term-
inal and the vehicle’s frame or body.
l Never lean over the battery when making connections.
l Never attempt to charge a frozen battery. The battery could rupture
and explode. If you suspect that a battery may be frozen, remove the
vent caps and check the f!uid. If there seems to be no fluid, or if you
see ice, do not attempt to charge the battery until the fluid thaws.
CAUTION:
l Be careful to connect the,charging cables to the correct battery and
generator terminals (positive to positive and negative to negative). If
the charging cables are connected positive to negative, it may cause
serious battery or generator damage.
l Do not attempt to start an automobile engine with the generator still
connected to the battery; this may damage the generator.
NOTE:
l The DC terminals may be used while the AC power is in use.
l An overloaded DC circuit will trip the DC circuit protector (push button
comes out). If this happens, wait a few minutes before pushing the circuit
protector to resume operation.

24
 6. STOPPING THE ENGINE

To stop the engine in an emergency, turn the ehgine switch to.the OFF posi-
tion.

In normal use:
1. Turn the AC circuit breaker to the OFF position.
Disconnect DC battery charging cables.

AC ~RCUIT BREAKER

2. Turn the engine switch to the OFF position.

(EM5000X) (EM5000SX)

ENGINE SWITCH

25
 3; Turn the fuel valve to the OFF position.

. .
FUEL VALVE

l High altitude operation

At high altitude, the standard carburetor air-fuel mixture will be excessively

rich. Performance will descrease, and fuel consumption will increase.

High altitude performance can be improved by installing a smaller diameter

main fuel jet in the carburetor and readjusting the pilot screw. If you always
operate the Generator at altitudes higher than 6,000 feet above sea level, have
your authorized Honda Generator dealer perform these carburetor modifica-
tions.
Even with suitable carburetor jetting, engine horsepower will descrease ap-
proximately 3.5% for each 1,000 foot increase in altitude. The affect of
altitude on horsepower will be greater than this if no carburetor.modification
is made.

CAUTlON: Operation of the Generator at an altitude lower than the car-

buretor is jetted foi- may result in reduced performance, overheating, and
serious engine damage caked ‘by an excessively lean air/fuel mixture.

26
 7. MAINTENANCE

Periodic maintenance and adjustment is necessary to keep the generator, in

good operating condition. Perform the service and inspection scheduled in the
table on the following page.

m. Shut off the engine before performing any maintenance. If the

engine must be run, make sure the area is well ventilated. Exhaust contains
poisonous carbon monoxide; exposure may cause loss of consciousness and
may lead to death.

CAUTION: Use only genuine Honda parts or their equivalent for mainte-
nance or repair. Replacement parts which are not of equivalent quality may
damage the generator.

Tool Kit

The tools supplied with the generator will help you to perform the owner-
maintenance procedures listed on the following page. Always keep this tool
kit with the generator.

D 1

10 x 12 mm WRENCH SCREW DRIVER’

: ., >

PLUG WRENCH DRIVER HANDLE

HANDLE BAR

TOOL BAG

27
Maintenance Schedule

First
Each month
use
~~~ 20’Lrs.
(3)

Check level
Engine oil
Change
Check
Air cleaner
Clean
Sediment cup and
fuel valve filter Clean
Soark olug Clean-Readjust
Soark arrester Clean
Valve clearance Check-Readiust
Fuel tank, strainer,Clean
and tank filter
Fuel line Check (Replace
Every 3 years (2)
if necessary)

NOTE: (1) Service more frequently when used in dusty areas.

(2) These items should be serviced by an authorized Honda dealer, unless the
owner has the proper tools and is mechanically proficient. See the Honda
Shop Manual.
(3) For professional commercial use, log hours of operation to determine proper
maintenance intervals.

28
Changing Oil

Drain the oil while the engine is still warm to assure rapid and complete drain-
ing.

1. Remove the oil filler cap and drain plug to drain the oil.
2. Install the drain plug, and tighten it securely.
3. Refill with the recommended oil (see page 9), and check the oil level.

OIL CAPACITY: 1.1 Q (1.16 US qt )

DRAIN PLUG

CAUTION: Used motor oil may cause skin cancer if repeatedly left in contact
with the skin for prolonged periods. Although this is unlikely unless you handle
used oil on a daily basis, it is still adviseable to thoroughly wash your hands with
soap and water as soon as possible after handling used oil.

NOTE: Please dispose of used motor oil in a manner that is compatible with the
environment. We suggest you take it in a sealed container to your local service
station for reclamation. Do not throw it in the trash or pour it on the ground.

29
Air Cleaner Service .

A dirty air cleaner will, restrict air flow to the carburetor. To prevent carbure-
tor malfunction, service the air cleaner regularly ,(page 28). Service more
frequently when operating the generator in extremely dusty areas.

m Never use gasoline or low flash point solvents for .cleaning the air
cleaner element. A fire or explosion could’ result from contaminants, such as
dust and dirt, being drawn through the carburetor, into the engine.

CAUTION: Never run the generator without the air cleaner. Rapid engine
wear will result.

1. Unsnap the air cleaner cover springs, remove the air cleaner cover, and
remove the element.

COVER AIR CLEANER

ELEMENT

COVER
SPRING ‘.

30
2. Wash the element in a solution of household detergent and warin water,
then rinse thoroughly, or wash in nonflammable or high flash point sol-
,vent. Allow the element to dry thoroughly.

3. Soak the element in clean engine oil and squeeze out the excess oil. The
engine will smoke during initial start-up if too much oil is left in the ele-
ment.

4. Reinstall the air cleaner element and the cover.

ELEMENT

31
Sediment Cup and Filter Cleaning

The sediment cup and filter prevent dirt or water which may be in the fuel
tank from entering the carburetor. If the engine has not been run for a long
time, the sediment cup and filter should be cleaned.

1. Turn the fuel valve to the OFF position. Remove the sediment cup, O-ring,
and filter.
2. Clean the sediment cup, O-ring, and filter in nonflammable or high flash
point solvent.
3. Reinstall the filter, O-ring, and sediment cup.

l Gasoline is extremely flammable and is explosive under certain conditions.

l After installing the sediment cup, check for fuel leaks, and make sure the
area is dry before starting the engine. Fuel vapor or spilled fuel may ignite.

FUEL VALVE

CUP

FUEL FILTER

0 -O-RING

/
SEDIMENT CUP
32
Spark Plug Service I

Recommended spark plug: BPR5ES (NGK)

WlGEPR-U (ND)

To ensure proper engine operation, the spark plug must be properly gapped
and free of deposits.

m If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler while it is hot.

1. Remove the spark plug cap.

2. Clean any dirt from around the spark plug base.
3. Use the wrench supplied in the tool kit to remove the spark plug.

4. Visually inspect the spark plug. Discard it if the insulator is cracked or

chipped. Clean the spark plug with a wire brush if it is to be reused.
5. Measure the plug gap with a feeler gauge. The.gap should be 0.7-0.8 mm
(0.028-0.031 in).

0.7-0.8 mm
(0.028-0.031 in)

33
 6. Check that the spark plug washer is in good condition, and thread the spark
plug in by hand to prevent cross-threading.

7. After the spark plug is seated, ,tighten with a spark plug wrench to com-
press the washer.

NOTE: If installing a new spark plug, tighten l/2 turn after the spark plug
seats to compress the washer. I,f. reinstalling a used spark plug,. tighten l/8-
1/4 turn after the spark plug seats to compress the washer.

CAUTION:
l The spark plug must be securely tightened. An impropefly tightened spark
plug can become very hot and-may cause engine damage.
0. Use only the recommended spark plugs or equivalent. Spark plugs which
have an improper heat range may cause engine damage.

34
 I
Spark Arrester Maintenance
This generator’s U.S.D.A., qualified spark arrester requires periodic mainte-
nance to ensure’ its effectiveness. It is illegal in some areas to operate an engine
without a spark arrester. Check local laws and regulations.
m
If the generator has been running, the muffler will be very hot.
Allow it to cool before proceeding. Be careful not to touch the muffler while
it is hot.

CAUTION: The spark arrester must be serviced every 100 hours to maintain
its efficiency.

1. Remove the 4 mm screw from the side of the muffler exhaust pipe. Use a
screwdriver to push in the spark arrester retaining tab on the opposite side
of the exhaust pipe, and remove the spark arrester.
2. Clean the carbon deposits from the spark arrester screen with a brush.
Check .the spark arrester screen for damage. Replace the spark arrester if
the screen is torn or punctured.
3. Reinstall the spark arrester, and tighten the screw securely.

ARRESTER

/
SPARK ARRESTER

35
8. TRANSPORTING/STORAGE

l Let the engine cool before transporting the generator or storing it indoors.
l When,transporting the generator, turn the engine switch and the fuel valve
to the OFF position, and keep the generator level to prevent fuel spillage.
Fuel vapor or spilled fuel may ignite.
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Drain the fuel -
a. With the fuel valve OFF, remove and empty the sediment cup.
FUEL VALVE

SEDIMENT CUP

b. Turn the fuel valve ON, and drain the gasoline in the fuel tank into a
suitable container.
c. Replace the sediment cup and tighten securely.

36
 d. Drain the carburetor by loosening the drain screw. Drain the gasoline
into a suitable container.

m Gasoline is extremely flammable and is explosive under certain

conditions. Perform this task in a well-ventilated area with the, engine stop-
ped. Do not smoke or allow flames or sparks in, the area during this proce-
dure.
DRAIN SCREW

3. Change the engine oil.

4. Remove the spark plug, and pour about a tablespoon of clean engine oil
into the cylinder. Crank the engine several revolutions to distribute the
oil, then reinstall the spark plug.
5. Slowly pull the starter grip until resistance is felt. At this point, the posi-
tion is coming up on its compression stroke and both the intake and ex-
haust valves are closed. Storing the engine in this position will help to
protect it from ‘internal corrosion.

6. Cover the engine to keep out dust.

7. Once a month, recharge the battery. (EM5000SX)
37
9. TROUBLESHOOTING

A.When the engine will hot start:

1. Is the engine switch on?
2. Does the oil alert lamp flash when the starter is pulled? ,_
3. Is there enough fuel?
4. Are all loads disconnected from the AC receptacles?
5. Is there a spark atthe spark plug?
a. Remove the spark plug cap, Clean any dust from around the spark
plug base, then remove the spark plug.
b. Install the spark plug in the plug cap.
c.‘Turn the engine switch on.
d. Grounding the side electrode to any engine ground, pull the recoil
starter to see if sparks jump across the gap.

m If any fuel has been spilled, make sure the area is dry before test-
ing the spark plug. Fuel vapor or spilled fuel may ignite. Perform this test in
a well-ventilated area.

e. If there are no sparks, replace’the plug.

f. If the new spark plug does not spark, take the generator to an author-
ized Honda dealer.

OIL
I
ALERT LAMP I

ENGINE
SWITCH

38
 6. Is gasoline reaching the carburetor?
To check, place a suitable container under the drain tube, turn the fuel
valve on and loosen the drain screw. Fuel should flow out freely. If OK,
try to start the engine according to the instructions.

m If any fuel has been spilled, make sure the are is dry before at-
tempting to start the engine. Fuel vapor or spilled fuel may ignite. Perform
this test in a well-ventilated area.

DRAINsSCREW

1.
/
.
7. If the engine still does not start, take the generator to an authorized
Honda dealer.

B. When the engine starts but stops immediately;

1. Check the oil alert lamp.
If the oil alert lamp flaslies when the starter is pulled, check the engine
oil level and fill with the recommended oil.
2. Restart the engine.

C. No electricity at the AC receptacles:

1. Is the AC circuit breaker on?
2. Check the electrical appliance or equipment for any defects.

D. No electricity at the DC terminals.

1. Is the DC circuit breaker on?

39
10. WIRING DIAGRAM
(‘EM5000SX)

-
 ..- _............
*,NOAozL-mz/mL I
11. SPECIFICATIONS
Dimensions
Model EM5000SX EM5000X

Power equipment description code EA7

Length x Width’x Height 655 x 510 x 490 mm (25.8 x 20.1 x 19.3 in)

Dry weight 80 kg (176.4 lb) 78 kg (171.9 lb)

Engine
Model GX340

Engine type 4-stroke, overhead valve, single cylinder

Displacement (Bore x Stroke) 337 cc (20.6 cu in) 182 x 64 mm (3.2 x 2.5 in)]

Compression ratio 8.0 : 1

Engine speed 3,600 r.p.m.

Cooling system Forced air

Ignition system Transistorized magneto

Oil capacity 1.1 ]z (1.16 USqt)

Fuel tank capacity 17.0 Q (4.5 US gal)

Spark plug IBPRSES (NGK), WlGEPR-U (ND)

Generator
Model EM5000SX EM5000X

Type :A

Rated voltage 120/24OV

Rated frequency 60 Hz
AC output Rated ampere 37.5118.8A

Rated output 4,500 VA

Maximum ourtput 5,000 VA

DC output Only for charging 12V automotive batteries.
Maximum charging output = 8.3A

42
 ‘l2JNSTALLATION OF OPTIONAL PARTS

Remote Control Kit (EM5000SX only)

1. Install the relay box on the right side of the generator.

2. Remove the blind 8-P connector from the back of the control box and
connect the relay box connector instead.

3. Connect the remote control cable to the remote control and relay box.

REMOTE CONTROL
CARI F

’ REMOTE CONTROL BOX

NOTE: l Connect the blind connector when not using the remote control.
l Engine will not start unless the blind connector is connected.

43
Remote Control Box

ENGINE STARTER
SWITCH BUTTON

Starting the engine with remote control

1. Turn the fuel valve to the ON position.
2. Turn the auto-throttle switch to the OFF position.
3. Turn off the engine switch at the generator and remove the key.
4. Turn the relay box switch to the ON position.
5. Turn the engine switch at the remote control box to the ON position.

6. Press the starter button until the pilot lamp comes on.

Stopping the engine

1. Turn the engine switch at the remote control box to the OFF position.
2. Turn the relay box switch to the OFF position.
3. Turn the fuel valve to the OFF position.

45
Battery Tray Kit (EM!jOOOSX only)

1. Install the battery guard on the frame.

Set the battery tray on the battery guard and tighten the bolts.
2. Route the starter cab!e under the tank and connect it to the starter solenoid.
3. Connect the ground cable to the generator rear housing.
4. Set the battery on the battery tray and secure with the battery bracket.
Connect the starter cable to the battery positive (+) terminal first, then to
the negative (-) terminal. When disconnecting, disconnect at the battery
negative (-) terminal first.. _
5. Install the battery guard plate on the battery guard.
 STARTER

STARTER

lor more

\ CABLE

BATTERY
-GUARD

\
BATTERY / BATTERY
GUARD PLATE

45
 4-Wheel Kit Installation

1. Install the four wheels on the axle shaft.

2. Install the axle ak’mbly on the generator using four bolts and nuts.

Inside.

WHEEL! STOPPER

NOTE: Install the shaft with wheel stopper facing engine side.

48
 13. WARRANTY SERVICE

Owner Satisfaction

Your satisfaction and goodwill are important to your dealer and to us. All
Honda warranty details are explained in the Distributor’s Limited Warran-
ty. Normally, any problems concerning the product will be handled by your
dealer’s service department. If you have a warranty problem that has not
been handled to your satisfaction, we suggest you take the following
action:

l Discuss your problem with a member of dealership management. Often

complaints can be quickly resolved at that level. If the problem has
already been reviewed with the Service Manager, contact the owner of
the dealership or the General Manager.

l If your problem still has not been resolved to your satisfaction, contact:
American Honda Motor Co., Inc.
P.O. Box 100021
Duluth, Georgia 30136-9421
Telephone: (404) 497-6400
We will need the following information in order to assist you:

-. Your name, address, and telephone number

- Product model and serial number
- Date of purchase
- Dealer name and address
- Nature of the problem

After reviewing all the facts involved, you will be advised of what action
can be taken. Please bear,in mind that your problem will likely be resolved
at the dealership, using the dealer’s facilities, equipment, and personnel,
so it is very important that your initial contact be with the dealer.

Your purchase of a Honda product is greatly appreciated by both your

dealer an’d American Honda Motor Co., Inc. We want to assist you in every
way possible to assure your complete satisfaction with your purchase.

49
Current customer service contact information:

United States, Puerto Rico, and U.S. Virgin Islands:

Honda Power Equipment dealership personnel are trained professionals. They should
be able to answer any question you may have. If you encounter a problem that your
dealer does not solve to your satisfaction, please discuss it with the dealership's
management. The Service Manager or General Manager can help. Almost all problems
are solved in this way.

If you are dissatisfied with the decision made by the dealership's management, contact
the Honda Power Equipment Customer Relations Office. You can write:

American Honda Motor Co., Inc.

Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST

When you write or call, please provide the following information:

• Model and serial numbers

• Name of the dealer who sold the Honda power equipment to you

• Name and address of the dealer who services your equipment

• Date of purchase

• Your name, address, and telephone number

• A detailed description of the problem

 MEMO

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MEMO

51
 MEMO

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